铸造铝合金车门“材料-结构-工艺”一体化设计

为实现轻量化目标,文章针对某款电动汽车后门进行“材料-结构-工艺”的一体化设计。首先进行车门4种常见工况下的多目标拓扑优化,分析出设计空间;然后结合精密铸造工艺和ZL205A铜铝合金材料特性对车门进行详细设计;最后进行新型车门模态及刚度性能分析,以验证结构的合理性。对满足设计要求的车门进行试制和性能测试试验,结果表明,新型铸铝车门在满足各性能指标的同时,质量减轻13.66%,达成轻量化设计目标。

In order to achieve the goal of lightweight, this paper presents a material-structure-process integrated design for the rear door of an electric vehicle. Firstly, the multi-objective topology optimization under four common working conditions of the door is carried out, and the design space is analyzed. Secondly, the detailed design of the door is performed by combining the precision casting process and the material characteristics of ZL205A copper and aluminum alloy. Finally, the modal and stiffness performance analysis of the new door is conducted to verify the rationality of the structure. The trial production and performance testing experiments of the doors that meet the design requirements show that the new cast aluminum alloy doors meet the performance indicators while reducing the mass by 13.66%, achieving the lightweight design goal.